An additive manufacturing method produces a 3D part utilizes electrophotography-based additive manufacturing and molding processes. A layered structure having a cavity is printed on a build platform using at least one electrophotographic (EP) engine to develop imaged layers of powder material, and a transfusion assembly to stack and fuse the imaged layers on the build platform. Molding material is deposited into the cavity as the layered structure is printed, using a deposition unit. The molding material solidifies to form at least a portion of the 3D part, which may also include portions formed from imaged powder material.

Additive manufacturing systems and methods used for creating 3D parts from continuous-fiber reinforced composites such as, e.g., carbon-fiber or glass-fiber pre-impregnated tape are provided. The systems and methods lay tape in successive layers and cut each layer according to a 2D slice of a 3D CAD file. During the placement of each piece of tape, a laser welds the tape to other tape, eliminating the need for post-processing of each layer. By utilizing tape instead of large fiber-reinforced sheets, the systems and methods described herein reduce waste compared to known manufacturing techniques.

Additive manufacturing systems and methods used for creating 3D parts from continuous-fiber reinforced composites such as, e.g., carbon-fiber or glass-fiber pre-impregnated tape are provided. The systems and methods lay tape in successive layers and cut each layer according to a 2D slice of a 3D CAD file. During the placement of each piece of tape, a laser welds the tape to other tape, eliminating the need for post-processing of each layer. By utilizing tape instead of large fiber-reinforced sheets, the systems and methods described herein reduce waste compared to known manufacturing techniques.

A 3D object according to the invention involves substrate layers infiltrated by a hardened material. The 3D object may be fabricated by a method comprising the following steps: Flatten a substrate layer. Position powder on all or part of a substrate layer. Repeat this step for the remaining substrate layers. Stack the substrate layers. Transform the powder into a substance that flows and subsequently hardens into the hardened material. The hardened material solidifies in a spatial pattern that infiltrates positive regions in the substrate layers and does not infiltrate negative regions in the substrate layers. In a preferred embodiment, the substrate is carbon fiber and excess substrate is removed by abrasion.

An apparatus and method for the automated manufacturing of three-dimensional (3D) composite-based objects is disclosed. The apparatus comprises a material feeder, a printer, a powder system, a transfer system, and optionally a fuser. The method comprises inserting a stack of substrate sheets into a material feeder, transferring a sheet of the stack from the material feeder to a printer, depositing fluid on the single sheet while the sheet rests on a printer platen, transferring the sheet from the printer to a powder system, depositing powder onto the single sheet such that the powder adheres to the areas of the sheet onto which the printer has deposited fluid, removing any powder that did not adhere to the sheet, optionally melting the powder on the substrate, and repeating the steps for as many additional sheets as required for making a specified 3D object.

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

A shaping apparatus includes a storage section that stores in advance a first relationship between a temperature of a shaping material and a heating time at a time at which oxidation of the shaping material starts as the shaping material is heated; and a control section that estimates a timing at which the oxidation of a material layer starts, based on an acquisition result from a temperature acquisition section, a measurement result from a time measurement section, and the first relationship stored in the storage section when the material layer on a conveyance body is preheated by a preheating section, and reduces a front surface temperature of the material layer on the conveyance body before the oxidation of the material layer starts.

An additive manufacturing system comprising a transfer medium configured to receive the layers from a imaging engine, a heater configured to heat the layers on the transfer medium, and a layer transfusion assembly that includes a build platform, and is configured to transfuse the heated layers onto the build platform in a layer-by-layer manner to print a three-dimensional part.

A shaping plate to be set on a shaping stage of a shaping system for performing shaping by an additive manufacturing method includes a water-insoluble base substrate and an underlying layer containing a water-soluble material on at least one surface of the base substrate, wherein the base substrate has a plurality of through holes that extend in the direction intersecting the surface provided with the underlying layer.